Method of making a nicotine containing sheet

ABSTRACT

A method of making a nicotine containing sheet is provided, including steps of combining a source of nicotine salt having a cellulose content of less than about 5% by weight on a dry weight basis with a separate source of fibrous material having a nicotine salt content of less than about 5% by weight on a dry weight basis to form a mixture; and drying the mixture to form a sheet.

The present invention relates to methods of making sheets comprisingnicotine. The present invention also relates to methods of makingaerosol-generating rods comprising gathered sheets comprising nicotine.

Electronic cigarettes (so-called ‘e-cigarettes’) and otherelectrically-operated smoking devices that vaporise a liquid formulationcomprising nicotine to form a nicotine-containing aerosol that isinhaled by a user are known in the art. For example, WO 2009/132793 A1discloses an electrically heated smoking system comprising a shell and areplaceable mouthpiece wherein the shell comprises an electric powersupply and electric circuitry. The mouthpiece comprises a liquid storageportion, a capillary wick having a first end that extends into theliquid storage portion for contact with liquid therein, and a heatingelement for heating a second end of the capillary wick. In use, liquidis transferred from the liquid storage portion towards the heatingelement by capillary action in the wick. Liquid at the second end of thewick is vaporised by the heating element.

Handling of the liquid formulations used in e-cigarettes may becumbersome or undesirable for a user. It would be desirable to provideaerosol-generating articles that provide a similar nicotine delivery toconventional cigarettes and that do not require the handling of a liquidformulation by the user.

According to the invention there is provided a method of making anicotine containing sheet comprising the steps of: combining a source ofnicotine salt having a cellulose content of less than about 5% by weighton a dry weight basis with a separate source of fibrous material havinga nicotine salt content of less than about 5% by weight on a dry weightbasis to form a mixture; and drying the mixture to form a sheet.

According to the invention there is also provided a method of making anaerosol-generating rod comprising the steps of: combining a source ofnicotine salt having a cellulose content of less than about 5% by weighton a dry weight basis with a separate source of fibrous material havinga nicotine salt content of less than about 5% by weight on a dry weightbasis to form a mixture; drying the mixture to form a sheet; gatheringthe sheet transversely relative to a longitudinal axis thereof;circumscribing the gathered sheet with a wrapper to form a rod; andsevering the rod into a plurality of discrete aerosol-generating rods.

As used herein with reference to the invention, the term “sheet” denotesa laminar element having a width and length substantially greater thanthe thickness thereof.

As used herein with reference to the invention, the term “rod” is usedto describe a generally cylindrical element of substantially circular,oval or elliptical cross-section.

As used herein with reference to the invention, the term “gathered”denotes that the sheet is convoluted, folded, or otherwise compressed orconstricted substantially transversely to the cylindrical axis of therod.

Sheets made by methods according to the invention do not compriseflowable liquid. Consequently, users of aerosol-generating articlescomprising aerosol-generating rods made by methods according to theinvention are advantageously not required to handle liquid formulations.

E-cigarettes typically use a liquid formulation comprising free nicotinebase. Nicotine salts may be more stable than free nicotine base.Consequently, sheets made by methods according to the invention andaerosol-generating rods made by methods according to the invention mayadvantageously have longer shelf lives than liquid formulations typicalused in e-cigarettes.

Aerosol-generating rods made by methods according to the invention maygenerate a nicotine-containing aerosol when heated to temperatures lowerthan about 300° C. For example, aerosol-generating rods made by methodsaccording to the invention may generate a nicotine-containing aerosolwhen heated to temperatures lower than about 250° C. or lower than about220° C. Aerosol-generating rods made by methods according to theinvention may generate a nicotine-containing aerosol when heated totemperatures as low as between about 120° C. and about 140° C.Consequently, there may advantageously be no need to use a large devicewith high battery power in order to generate aerosols with high levelsof nicotine from aerosol-generating rods made by methods according tothe invention.

The source of nicotine salt may have a cellulose content of less thanabout 4% by weight on a dry weight basis, less than about 3% by weighton a dry weight basis, less than about 2% by weight on a dry weightbasis or less than about 1% by weight on a dry weight basis.

The source of nicotine salt may comprise substantially no cellulosicmaterial.

The source of nicotine salt may have a nicotine salt content of at leastabout 96% by weight on a dry weight basis, at least about 97% by weighton a dry weight basis, at least about 98% by weight on a dry weightbasis or at least about 99% by weight on a dry weight basis. The sourceof nicotine salt may have a nicotine salt content of about 100% byweight on a dry weight basis.

Advantageously, the weight ratio of nicotine salt to cellulose in thesource of nicotine salt on a dry weight basis is at least about 25:1, atleast about 40:1, at least about 50:1 or at least about 100:1.

The source of nicotine salt may comprise one or more nicotine salts.

For example, the source of nicotine salt may comprise one or more saltsof acids selected from the group consisting of acetic acid, benzoicacid, carbonic acid, citric acid, gallic acid, hydrochloric acid, lacticacid, lauric acid, levulinic acid, malic acid, malonic acid, oxalicacid, oxaloacetic acid, palmitic acid, pyruvic acid, phosphoric acid,salicylic acid, sorbic acid, stearic acid, sulfuric acid and tartaricacid.

Advantageously, the source of nicotine salt may comprise one or morenicotine salts of carboxylic acids.

Advantageously, the source of nicotine salt may comprise one or moremonoprotic nicotine salts.

As used herein, the term “monoprotic nicotine salt” is used to describea nicotine salt of a monoprotic acid.

Advantageously, the source of nicotine salt comprises one or morenicotine salts of monoprotic carboxylic acids.

Advantageously, the source of nicotine salt may comprise one or morenicotine salts of monoprotic carboxylic acids selected from the groupconsisting of acetic acid, benzoic acid, gallic acid, lactic acid,lauric acid, levulinic acid, palmitic acid, pyruvic acid, sorbic acidand stearic acid. The source of nicotine salt may comprise one or morepolyprotic nicotine salts.

As used herein, the term “polyprotic nicotine salt” is used to describea nicotine salt of a polyprotic acid.

For example, the source of nicotine salt may comprise one or morenicotine salts of diprotic carboxylic acids such as malic acid, oxalicacid and tartaric acid.

For example, the source of nicotine salt may comprise one more nicotinesalts of triprotic carboxylic acids such as citric acid.

Advantageously, at least about 20% by weight of the nicotine salts inthe source of nicotine salt are monoprotic.

For example, at least about 30% by weight, at least about 40% by weight,at least about 50% by weight, at least about 60% by weight, at leastabout 70% by weight, at least about 80% by weight or at least about 90%by weight of the nicotine salts in the source of nicotine salt may bemonoprotic.

Advantageously, the source of nicotine salt may comprise five or fewernicotine salts. The source of nicotine salt may comprise four or fewernicotine salts, three or fewer nicotine salts or two or fewer nicotinesalts.

Advantageously the weight ratio of major nicotine salt to total nicotinesalt in the source of nicotine salt on a dry weight basis may be atleast about 2:3.

As used herein with reference to the source of nicotine salt, the term“major nicotine salt” is used to describe the nicotine salt in thesource of nicotine salt in the greatest amount by weight on a dry weightbasis.

The weight ratio of major nicotine salt to total nicotine salt in thesource of nicotine salt on a dry weight basis may advantageously be atleast about 3:4, at least about 4:5 or at least about 5:6.

Advantageously, the source of nicotine salt may comprise a singlenicotine salt.

More advantageously, the source of nicotine salt may comprise a singlemonoprotic nicotine salt.

Most advantageously, the source of nicotine salt may comprise a singlenicotine salt of a monoprotic carboxylic acid.

Advantageously, the source of nicotine salt may comprise one or morenicotine salts of acids having an atmospheric boiling point of betweenabout 150° C. and about 350° C.

The source of nicotine salt may advantageously comprise one or morenicotine salts of acids having an atmospheric boiling point of betweenabout 230° C. and about 270° C.

The combining step may comprise combining the source of nicotine saltand the source of fibrous material with one or more additionalcomponents to form the mixture.

Advantageously, at least about 20% by weight of the nicotine salts inthe mixture are monoprotic.

For example, at least about 30% by weight, at least about 40% by weight,at least about 50% by weight, at least about 60% by weight, at leastabout 70% by weight, at least about 80% by weight or at least about 90%by weight of the nicotine salts in the mixture may be monoprotic.

It will be appreciated that sheets made by methods according to theinvention may have the same percentages by weight on a dry weight basisand weight ratios on a dry weight basis of components as the mixturesformed in the combining steps of methods according to the invention.

Advantageously, the mixture may comprise five or fewer nicotine salts.

The mixture may comprise four or fewer nicotine salts, three or fewernicotine salts or two or fewer nicotine salts.

Advantageously the weight ratio of major nicotine salt to total nicotinesalt in the mixture on a dry weight basis may be at least about 2:3.

As used herein with reference to the mixture, the term “major nicotinesalt” is used to describe the nicotine salt in the mixture in thegreatest amount by weight on a dry weight basis.

Advantageously, the mixture may comprise a single nicotine salt.

The weight ratio of major nicotine salt to total nicotine salt in themixture on a dry weight basis may advantageously be at least about 3:4,at least about 4:5 or at least about 5:6.

More advantageously, the mixture may comprise a single monoproticnicotine salt.

Most advantageously, the mixture may comprise a single nicotine salt ofa monoprotic carboxylic acid.

Inclusion of a single nicotine salt may advantageously allow for bettercontrol of the aerosol formed by heating an aerosol-generating rodcomprising the sheet at a specific temperature and over time.

Advantageously, the mixture may have a total nicotine salt content of atleast about 1% by weight on a dry weight basis.

The mixture may advantageously have a total nicotine salt content of atleast about 2% by weight on a dry weight basis or at least about 3% byweight on a dry weight basis.

Advantageously, the mixture may have a total nicotine salt content ofless than about 30% by weight on a dry weight basis.

The mixture may advantageously have a total nicotine salt content ofless than about 30% by weight on a dry weight basis, less than about 20%by weight on a dry weight basis, less than about 10% by weight on a dryweight basis or less than about 6% by weight on a dry weight basis.

The mixture may have a total nicotine salt content of less than about 5%by weight on a dry weight basis or less than about 4% by weight on a dryweight basis.

The mixture may have a total nicotine salt content of between about 1%and about 30% by weight on a dry weight basis, between about 1% andabout 20% by weight on a dry weight basis, between about 1% and about10% by weight on a dry weight basis, between about 1% and about 6% byweight on a dry weight basis, between about 1% and about 5% by weight ona dry weight basis or between about 1% and about 4% by weight on a dryweight basis.

The mixture may have a total nicotine salt content of between about 2%and about 30% by weight on a dry weight basis, between about 2% andabout 20% by weight on a dry weight basis, between about 2% and about10% by weight on a dry weight basis, between about 2% and about 6% byweight on a dry weight basis, between about 2% and about 5% by weight ona dry weight basis or between about 2% and about 4% by weight on a dryweight basis.

The mixture may have a total nicotine salt content of between about 3%and about 30% by weight on a dry weight basis, between about 3% andabout 20% by weight on a dry weight basis, between about 3% and about10% by weight on a dry weight basis, between about 3% and about 6% byweight on a dry weight basis, between about 3% and about 5% by weight ona dry weight basis or between about 3% and about 4% by weight on a dryweight basis.

Advantageously, the mixture may have a tobacco nicotine salt content ofless than about 0.5% by weight on a dry weight basis.

As used herein with reference to the invention, the term “tobacconicotine salt” is used to describe nicotine salts occurring naturally inany tobacco material in the mixture.

The mixture may have a tobacco nicotine salt content of less than about0.4% by weight on a dry weight basis, less than about 0.3% by weight ona dry weight basis, less than about 0.2% by weight on a dry weight basison less than about 0.1% by weight on a dry weight basis. Advantageously,the weight ratio of tobacco nicotine salt to total nicotine salt in themixture on a dry weight basis may be less than about 1:5.

The weight ratio of tobacco nicotine salt to total nicotine salt in themixture on a dry weight basis may advantageously be less than about1:10, less than about 1:15 or less than about 1:25.

The mixture may contain substantially no tobacco nicotine salt.

The percentages by weight and weight ratios of nicotine salts recitedherein are those measured by liquid chromatography.

Advantageously, the source of fibrous material may comprise cellulosefibres or nylon. More advantageously, the source of fibrous material maycomprise cellulose fibres. The source of fibrous material may have anicotine salt content of less than about 4% by weight on a dry weightbasis, less than about 3% by weight on a dry weight basis, less thanabout 2% by weight on a dry weight basis or less than about 1% by weighton a dry weight basis.

The source of fibrous material may comprise substantially no nicotinesalts.

The source of fibrous material may have a fibrous material content of atleast about 96% by weight on a dry weight basis, at least about 97% byweight on a dry weight basis, at least about 98% by weight on a dryweight basis or at least about 99% by weight on a dry weight basis. Thesource of fibrous material may have a fibrous material content of about100%.

Advantageously, the weight ratio of fibrous material to nicotine salt inthe source of fibrous material on a dry weight basis is at least about25:1, at least about 40:1, at least about 50:1 or at least about 100:1.

Advantageously, the mixture may have a total fibrous material content ofat least about 1% by weight on a dry weight basis.

Advantageously, the mixture may have a total fibrous material content ofless than about 70% by weight on a dry weight basis.

The mixture may have a total fibrous material content of less than about60% by weight on a dry weight basis, less than about 50% by weight on adry weight basis, less than about 40% by weight on a dry weight basis,less than about 30% by weight on a dry weight basis, less than about 20%by weight on a dry weight basis or less than about 10% by weight on adry weight basis

The mixture may have a total fibrous material content of between about1% and about 70% by weight on a dry weight basis, between about 1% andabout 60% by weight on a dry weight basis, between about 1% and about50% by weight on a dry weight basis, between about 1% and about 40% byweight on a dry weight basis, between about 1% and about 30% by weighton a dry weight basis, between about 1% and about 20% by weight on a dryweight basis or between about 30% and about 10% by weight on a dryweight basis.

Advantageously, the weight ratio of fibrous material to nicotine salt inthe mixture on a dry weight basis may be between about 30:1 and about1:5 or between about 15:1 and about 1:3.

The combining step may comprise combining the source of nicotine salt,the source of fibrous and one or more additional components in a singlestep to form the mixture.

The combining step may comprise combining the source of nicotine salt,the source of fibrous and one or more additional components in multiplesteps to form the mixture.

For example, the combining step may comprise combining the source ofnicotine salt, the source of fibrous and one or more additionalcomponents in two steps or three steps to form the mixture.

The combining step may comprise: a first step of combining the source ofnicotine salt and the source of fibrous material to form a premixture;and a second step of combining one or more additional components withthe premixture to form the mixture.

The combining step may comprise: a first step of combining the source ofnicotine salt and one or more additional components to form apremixture; and a second step of combining the source of fibrousmaterial with the premixture to form the mixture.

The combining step may comprise: a first step of combining the source offibrous material and one or more additional components to form apremixture; and a second step of combining the source of nicotine saltwith the premixture to form the mixture.

The combining step may comprise: a first step of combining the source ofnicotine salt and the source of fibrous material to form a firstpremixture; a second step of combining one or more additional componentsto form a second premixture; and a third step of combining the firstpremixture and the second premixture to form the mixture.

The combining step may comprise: a first step of combining the source ofnicotine salt and one or more additional components to form a firstpremixture; a second step of combining the source of fibrous materialand one or more additional components to form a second premixture; and athird step of combining the first premixture and the second premixtureto form the mixture.

Advantageously, the combining step may comprise combining cellulosepowder with the source of nicotine salt and the source of fibrousmaterial to form the mixture.

Advantageously, the cellulose powder may have an average particle sizeof less than about 60 microns. Inclusion of cellulose powder having anaverage particle size of less than about 60 microns may facilitateformation of the sheet.

Advantageously the weight ratio of cellulose powder to total cellulosicmaterial in the mixture on a dry weight basis may be greater than about1:2.

The weight ratio of cellulose powder to total cellulosic material in themixture on a dry weight basis may advantageously be greater than about2:3, greater than about 3:4, greater than about 4:5 or greater thanabout 5:6.

Advantageously, the weight ratio of cellulose powder to nicotine salt inthe mixture on a dry weight basis may be between about 18:1 and about5:1 or between about 16:1 and about 8:1.

Advantageously, the weight ratio of cellulose powder to fibrous materialin the mixture on a dry weight basis may be between about 30:1 and about10:1 or between about 25:1 and about 15:1.

Advantageously, the mixture may have a total cellulosic material contentof at least about 30% by weight on a dry weight basis.

The mixture may have a total cellulosic material content of at leastabout 35% by weight on a dry weight basis or at least about 40% byweight on a dry weight basis.

Advantageously, the mixture may have a total cellulosic material contentof less than about 60% by weight on a dry weight basis.

The mixture may have a total cellulosic material content of less thanabout 55% by weight on a dry weight basis or less than about 50% byweight on a dry weight basis.

The mixture may have a total cellulosic material content of betweenabout 30% and about 60% by weight on a dry weight basis, between about30% and about 55% by weight on a dry weight basis or between about 30%and about 50% by weight on a dry weight basis.

The mixture may have a total cellulosic material content of betweenabout 35% and about 60% by weight on a dry weight basis, between about35% and about 55% by weight on a dry weight basis or between about 35%and about 50% by weight on a dry weight basis.

The mixture may have a total cellulosic material content of betweenabout 40% and about 60% by weight on a dry weight basis, between about40% and about 55% by weight on a dry weight basis or between about 40%and about 50% by weight on a dry weight basis.

Advantageously, the combining step may comprise combining sugar with thesource of nicotine salt and the source of fibrous material to form themixture.

As used herein with reference to the invention, the term “sugar” is usedto describe monosaccharides, disaccharides, oligosaccharides comprisingthree to ten monosaccharide units and sugar alcohols.

Inclusion of sugar may advantageously improve the malleability andpliability of the sheet compared to a sheet in which no sugar isincluded. This may facilitate gathering of the sheet to form a rod asdescribed further below.

The mixture may advantageously comprise one or more sugars selected fromthe group consisting of disaccharides and sugar alcohols.

For example, the mixture may comprise one or more disaccharides such aslactose, sucrose and trehalose, one or more sugar alcohols such asmannitol and sorbitol or a combination of one or more disaccharides andone or more sugar alcohols.

Advantageously, the weight ratio of reducing sugar to total sugar in themixture on a dry weight basis may be less than about 1:2.

The percentages by weight and weight ratios of sugars recited herein arethose measured by liquid chromatography.

The weight ratio of reducing sugar to total sugar in the mixture on adry weight basis may advantageously be less than about 1:4, less thanabout 1:6, less than about 1:8 or less than about 1:10.

The mixture may comprise substantially no reducing sugar.

Advantageously, the weight ratio of cyclic sugar to total sugar in themixture on a dry weight basis may be less than about 1:3.

The weight ratio of cyclic sugar to total sugar in the mixture on a dryweight basis may advantageously be less than about 1:4, less than about1:6, less than about 1:8 or less than about 1:10.

The mixture may comprise substantially no cyclic sugar.

Advantageously, the weight ratio of formaldehyde-generating sugar tototal sugar in the mixture on a dry weight basis may be less than about1:3.

As used herein with reference to the invention, the term“formaldehyde-generating sugar” is used to describe sugar that whenpyrolysed can lead to the formation of formaldehyde.

The weight ratio of formaldehyde-generating sugar to total sugar in themixture on a dry weight basis may advantageously be less than about 1:4,less than about 1:6, less than about 1:8 or less than about 1:10.

The mixture may comprise substantially no formaldehyde-generating sugar.

Advantageously, the mixture may comprise one or more sugars alcohols.

Advantageously, the mixture may have a sugar alcohol content of at leastabout 10% by weight on a dry weight basis.

The mixture may have a sugar alcohol content of at least about 15% byweight on a dry weight basis, at least about 20% by weight on a dryweight basis or at least about 25% by weight on a dry weight basis.

Advantageously, the mixture may have a sugar alcohol content of lessthan about 40% by weight on a dry weight basis.

The mixture may have a sugar alcohol content of less than about 35% byweight on a dry weight basis or less than about 30% by weight on a dryweight basis.

The mixture may have a sugar alcohol content of between about 10% andabout 40% by weight on a dry weight basis, between about 10% and about35% by weight on a dry weight basis or between about 10% and about 30%by weight on a dry weight basis.

The mixture may have a sugar alcohol content of between about 15% andabout 40% by weight on a dry weight basis, between about 15% and about35% by weight on a dry weight basis or between about 15% and about 30%by weight on a dry weight basis.

The mixture may have a sugar alcohol content of between about 20% andabout 40% by weight on a dry weight basis, between about 20% and about35% by weight on a dry weight basis or between about 20% and about 30%by weight on a dry weight basis.

The mixture may have a sugar alcohol content of between about 25% andabout 40% by weight on a dry weight basis, between about 25% and about35% by weight on a dry weight basis or between about 25% and about 30%by weight on a dry weight basis.

Advantageously, the mixture may comprise mannitol, sorbitol or acombination thereof. More advantageously, the mixture may comprisemannitol.

Pyrolysis of sorbitol and mannitol advantageously does not lead to theformation of formaldehyde.

Advantageously the weight ratio of sugar alcohol to total sugar in themixture on a dry weight basis may be at least about 2:3.

The weight ratio of sugar alcohol to total sugar in the mixture on a dryweight basis may advantageously be at least about 3:4, at least about4:5 or at least about 5:6.

Advantageously, the mixture may have a total sugar content of at leastabout 15% by weight on a dry weight basis.

The mixture may have a total sugar content of at least about 20% byweight on a dry weight basis, at least about 25% by weight on a dryweight basis or at least about 30% by weight on a dry weight basis.

Advantageously, the mixture may have a total sugar content of less thanabout 45% by weight on a dry weight basis.

The mixture may have a total sugar content of less than about 40% byweight on a dry weight basis, less than about 35% by weight on a dryweight basis or less than about 30% by weight on a dry weight basis.

The mixture may have a total sugar content of between about 15% andabout 45% by weight on a dry weight basis, between about 15% and about40% by weight on a dry weight basis, between about 15% and about 35% byweight on a dry weight basis or between about 15% and about 30% byweight on a dry weight basis.

The mixture may have a total sugar content of between about 20% andabout 45% by weight on a dry weight basis, between about 20% and about40% by weight on a dry weight basis, between about 20% and about 35% byweight on a dry weight basis or between about 20% and about 30% byweight on a dry weight basis.

The mixture may have a total sugar content of between about 25% andabout 45% by weight on a dry weight basis, between about 25% and about40% by weight on a dry weight basis, between about 25% and about 35% byweight on a dry weight basis or between about 25% and about 30% byweight on a dry weight basis.

Advantageously, the mixture may have a combined fructose and glucosecontent of less than about 5% by weight on a dry weight basis.

As used herein with reference to the invention, the term “combinedfructose and glucose content” is used to describe the total percentageby weight of fructose and glucose in the mixture.

The mixture may have a combined fructose and glucose content of lessthan about 3% by weight on a dry weight basis, less than about 2% byweight on a dry weight basis or less than about 1% by weight on a dryweight basis.

Advantageously, the weight ratio of fructose and glucose to total sugarin the mixture on a dry weight basis may be less than about 1:5.

The weight ratio of fructose and glucose to total sugar in the mixtureon a dry weight basis may advantageously be less than about 1:10, lessthan about 1:15 or less than about 1:25.

The mixture may contain substantially no fructose or glucose.

Advantageously, the weight ratio of sugar to nicotine salt in themixture on a dry weight basis may be between about 12:1 and about 5:2 orbetween about 10:1 and about 5:1.

Advantageously, the weight ratio of sugar to fibrous material in themixture on a dry weight basis may be between about 25:1 and about 1:3 orbetween about 20:1 and about 1:2.

Advantageously, the weight ratio of sugar to cellulose powder in themixture on a dry weight basis may be between about 4:3 and about 1:2 orbetween about 1:1 and about 5:9.

Advantageously, the combining step may comprise combining a binder withthe source of nicotine salt and the source of fibrous material to formthe mixture.

Inclusion of a binder may advantageously facilitate manufacture of thesheet.

Inclusion of a binder may advantageously improve the homogeneity of thesheet compared to a sheet in which no binder is included.

The mixture may comprise a gum binder.

Advantageously, the mixture may comprise a natural gum binder.

Advantageously, the mixture may comprise one or more natural gum bindersselected from the group consisting of guar gum, xanthan gum and gumarabic.

Advantageously, the mixture may have a binder content of at least about1% by weight on a dry weight basis.

The mixture may have a binder content of at least about 2% by weight ona dry weight basis.

Advantageously, the mixture may a have a binder content of less thanabout 10% by weight on a dry weight basis.

The mixture may have a binder content of less than about 8% by weight ona dry weight basis, less than about 6% by weight on a dry weight basisor less than about 4% by weight on a dry weight basis.

The mixture may have a binder content of between about 1% and about 10%by weight on a dry weight basis, between about 1% and about 8% by weighton a dry weight basis, between about 1% and about 6% by weight on a dryweight basis or between about 1% and about 4% by weight on a dry weightbasis.

The mixture may have a binder content of between about 2% and about 10%by weight on a dry weight basis, between about 2% and about 8% by weighton a dry weight basis, between about 2% and about 6% by weight on a dryweight basis or between about 2% and about 4% by weight on a dry weightbasis.

Advantageously, the weight ratio of binder to nicotine salt in themixture on a dry weight basis may be between about 2:1 and about 1:2 orbetween about 3:2 and about 2:3.

Advantageously, the weight ratio of binder to fibrous material in themixture on a dry weight basis may be between about 3:1 and about 1:25 orbetween about 2:1 and about 1:10.

Advantageously, the weight ratio of binder to cellulose powder in themixture on a dry weight basis may be between about 1:10 and about 1:20or between about 1:12 and about 1:10.

Advantageously, the weight ratio of binder to sugar in the mixture on adry weight basis may be between about 1:5 and about 1:15 or betweenabout 1:8 and about 1:12.

1:18.

Advantageously, the combining step may comprise combining an aerosolformer with the source of nicotine salt and the source of fibrousmaterial to form the mixture.

Inclusion of an aerosol former may advantageously facilitate formationof a nicotine-containing aerosol upon heating on an aerosol-generatingrod comprising the sheet.

The aerosol-former may be any suitable known compound or mixture ofcompounds that, in use, facilitates formation of a dense and stableaerosol and that is substantially resistant to thermal degradation atthe operating temperature of an aerosol-generating article comprising anaerosol-forming substrate comprising the sheet.

Suitable aerosol-formers are known in the art and include, but are notlimited to: polyhydric alcohols, such as triethylene glycol,1,3-butanediol and glycerine; esters of polyhydric alcohols, such asglycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- orpolycarboxylic acids, such as dimethyl dodecanedioate and dimethyltetradecanedioate.

Advantageously, the mixture may comprise one or more polyhydricalcohols.

More advantageously, the mixture may comprise one or more aerosolformers selected from the group consisting of triethylene glycol,1,3-butanediol and glycerine.

The mixture may advantageously have an aerosol former content of atleast about 5% by weight on a dry weight basis.

The mixture may have an aerosol former content of at least about 10% byweight on a dry weight basis or at least about 15% by weight on a dryweight basis.

The mixture may advantageously have an aerosol former content of lessthan about 35% by weight on a dry weight basis.

The mixture may have an aerosol former content of less than about 30% byweight on a dry weight basis or less than about 25% by weight on a dryweight basis.

The mixture may have an aerosol former content of between about 5% andabout 35% by weight on a dry weight basis, between about 5% and about30% by weight on a dry weight basis or between about 5% and about 25% byweight on a dry weight basis.

The mixture may have an aerosol former content of between about 10% andabout 35% by weight on a dry weight basis, between about 10% and about30% by weight on a dry weight basis or between about 10% and about 25%by weight on a dry weight basis.

The mixture may have an aerosol former content of between about 15% andabout 35% by weight on a dry weight basis, between about 15% and about30% by weight on a dry weight basis or between about 15% and about 25%by weight on a dry weight basis.

Advantageously, the weight ratio of aerosol former to nicotine salt inthe mixture on a dry weight basis may be between about 15:1 and about3:1 or between about 10:1 and about 4:1.

Advantageously, the weight ratio of aerosol former to fibrous materialin the mixture on a dry weight basis may be between about 15:1 and about1:4 or between about 8:1 and about 1:2.

Advantageously, the weight ratio of aerosol former to cellulose powderin the mixture on a dry weight basis may be between about 2:3 and about1:3 or between about 1:2 and about 2:5.

Advantageously, the weight ratio of aerosol former to sugar in themixture on a dry weight basis may be about 2:3 and about 1:3 or betweenabout 1:2 and about 2:5.

Advantageously, the weight ratio of aerosol former to binder in themixture on a dry weight basis may be between about 15:1 and about 1:4 orbetween about 10:1 and about 1:3.

Advantageously, the weight ratio of aerosol-former to total nicotine inthe mixture on a dry weight basis may be less than about 15:1.

The weight ratio of the aerosol-former to total nicotine in the mixtureon a dry weight basis may advantageously be between about 3:1 and about10:1 or between about 4:1 and about 8:1.

As used herein with reference to the invention, the term “totalnicotine” is used to describe the total amount by weight of nicotine,nicotine base and nicotine salt in the mixture.

E-cigarettes typically use a liquid formulation in which the weightratio of aerosol former to nicotine on a dry weight basis is in therange of between about 20:1 and about 100:1. Upon heating such liquidformulations, an aerosol may be generated that has a low nicotineconcentration. This may result in users drawing deeper and longer puffsto provide a desired nicotine intake.

The combining step may comprise combining one or more flavourants withthe source of nicotine salt and the source of fibrous material to formthe mixture.

As used herein with reference to the invention, the term “flavourant” isused to describe any agent that, in use, imparts one or both of a tasteor aroma to an aerosol generated by an aerosol-forming substratecomprising the sheet.

The mixture may comprise one or more natural flavourants, one or moreartificial flavourants or a combination of one or more naturalflavourants and one or more artificial flavou rants.

For example, the mixture may comprise one or more flavourants thatprovide a flavour selected from the group consisting of menthol, lemon,vanilla, orange, wintergreen, cherry, and cinnamon.

The combining step may comprise combining one or more chemestheticagents with the source of nicotine salt and the source of fibrousmaterial to form the mixture.

As used herein with reference to the invention, the term “chemestheticagent” is used to describe any agent that, in use, is perceived in theoral or olfactory cavities of a user by means other than, or in additionto, perception via taste receptor or olfactory receptor cells.Perception of chemesthetic agents is typically via a ‘trigeminalresponse’, either via the trigeminal nerve, glossopharyngeal nerve, thevagus nerve, or some combination of these. Typically, chemestheticagents are perceived as hot, spicy, cooling, or soothing sensations.

The mixture may comprise one or more agents that are both a flavourantand a chemesthetic agent. For example, the mixture may comprise mentholor another flavourant that provides a cooling chemesthetic effect.

As used herein with reference to the invention, the term “menthol” isused to describe the compound 2-isopropyl-5-methylcyclohexanol in any ofits isomeric forms.

Advantageously, the mixture comprises less than about 15% by weight oftobacco material on a dry weight basis.

The tobacco material content of the mixture may advantageously be lessthan about 10% by weight on a dry weight basis, less than about 5% byweight on a dry weight basis, less than about 3% by weight on a dryweight basis, less than about 2% by weight on a dry weight basis or lessthan about 3% by weight on a dry weight basis.

The mixture may comprise substantially no tobacco material.

Advantageously, the combining step may comprise combining water with thesource of nicotine salt and the source of fibrous material to form themixture.

Where the combining step comprises combining water with the source ofnicotine salt and the source of fibrous material, the mixture may be anaqueous slurry.

For example, the method may comprise combining the source of nicotinesalt, the source of fibrous material, water and any other additionalcomponents such as cellulose powder, sugar, a binder and an aerosolformer to form an aqueous slurry.

Advantageously, the drying step comprises drying the mixture at atemperature of at least about 100° C.

The drying step may advantageously comprise drying the mixture at atemperature of at least about 110° C. or at least about 120° C.

Advantageously, the drying step comprises drying the mixture at atemperature of less than about 170° C.

The drying step may advantageously comprise drying the mixture at atemperature of less than about 160° C. or at least about 150° C.

The drying step may comprise drying the mixture at a temperature ofbetween about 100° C. and about 170° C., between about 100° C. and about160° C. or between about 100° C. and about 150° C.

The drying step may comprise drying the mixture at a temperature ofbetween about 110° C. and about 170° C., between about 110° C. and about160° C. or between about 110° C. and about 150° C.

The drying step may comprise drying the mixture at a temperature ofbetween about 120° C. and about 170° C., between about 120° C. and about160° C. or between about 120° C. and about 150° C.

Advantageously, the drying step comprises drying the mixture at atemperature of at least about 100° C. for at least about 5 seconds.

The drying step may advantageously comprise drying the mixture at atemperature of at least about 100° C. for at least about 30 seconds, atleast about 1 minute, at least about 2 minutes, at least about 3minutes, at least about 4 minutes or at least about 5 minutes.

The drying step may advantageously comprise drying the mixture at atemperature of at least about 110° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The drying step may advantageously comprise drying the mixture at atemperature of at least about 120° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The drying step may comprise drying the mixture at a temperature ofbetween about 100° C. and about 170° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The drying step may comprise drying the mixture at a temperature ofbetween about 100° C. and about 160° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The drying step may comprise drying the mixture at a temperature ofbetween about 100° C. and about 150° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The drying step may comprise drying the mixture at a temperature ofbetween about 110° C. and about 170° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The drying step may comprise drying the mixture at a temperature ofbetween about 110° C. and about 160° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The drying step may comprise drying the mixture at a temperature ofbetween about 110° C. and about 150° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The drying step may comprise drying the mixture at a temperature ofbetween about 120° C. and about 170° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The drying step may comprise drying the mixture at a temperature ofbetween about 120° C. and about 160° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The drying step may comprise drying the mixture at a temperature ofbetween about 120° C. and about 150° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

Advantageously, the drying step reduces the water content of the mixtureby at least about 50 percent.

The drying step may advantageously reduce the water content of themixture by at least about 60 percent, at least about 70 percent, atleast about 80 percent, at least about 90 percent or at least about 95percent.

The drying step may comprise drying the mixture using suitable knownmachinery and processes.

The drying step may comprise drying the mixture using one or both ofsteam and heated air.

The method may further comprise a step of spreading the mixture prior tothe drying step.

The method may further comprise a step of shaping the mixture prior tothe drying step. The method may further comprise the step of: extrudingthe mixture.

The method may further comprise the step of: rolling the mixture.

Advantageously, the method may further comprise the step of: casting themixture onto a support surface.

More advantageously, the method may comprise the steps of: casting themixture onto a support surface; drying the cast mixture to form a sheet;and removing the sheet from the support surface.

The method may further comprise the step of: drying the sheet after theremoving step. That is the method may comprise a first drying step ofdrying the cast mixture on the support surface to form a sheet and asecond drying step of drying the sheet after the step of removing thesheet from the support surface.

Advantageously, the second drying step comprises drying the sheet at atemperature of at least about 90° C.

The second drying step may advantageously comprise drying the sheet at atemperature of at least about 100° C. or at least about 110° C.

Advantageously, the second drying step comprises drying the sheet at atemperature of less than about 150° C.

The second drying step may advantageously comprise drying the sheet at atemperature of less than about 140° C. or at least about 130° C.

The second drying step may comprise drying the sheet at a temperature ofbetween about 90° C. and about 150° C., between about 90° C. and about140° C. or between about 90° C. and about 130° C.

The second drying step may comprise drying the sheet at a temperature ofbetween about 100° C. and about 150° C., between about 100° C. and about140° C. or between about 100° C. and about 130° C.

The second drying step may comprise drying the sheet at a temperature ofbetween about 110° C. and about 150° C., between about 110° C. and about140° C. or between about 110° C. and about 130° C.

Advantageously, the second drying step comprises drying the sheet at atemperature of at least about 90° C. for at least about 5 seconds.

The second drying step may advantageously comprise drying the sheet at atemperature of at least about 90° C. for at least about 30 seconds, atleast about 1 minute, at least about 2 minutes, at least about 3minutes, at least about 4 minutes or at least about 5 minutes.

The second drying step may advantageously comprise drying the sheet at atemperature of at least about 100° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The second drying step may advantageously comprise drying the sheet at atemperature of at least about 110° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The second drying step may comprise drying the sheet at a temperature ofbetween about 90° C. and about 150° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The second drying step may comprise drying the sheet at a temperature ofbetween about 90° C. and about 140° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The second drying step may comprise drying the sheet at a temperature ofbetween about 90° C. and about 130° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The second drying step may comprise drying the sheet at a temperature ofbetween about 100° C. and about 150° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The second drying step may comprise drying the sheet at a temperature ofbetween about 100° C. and about 140° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The second drying step may comprise drying the sheet at a temperature ofbetween about 100° C. and about 130° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The second drying step may comprise drying the sheet at a temperature ofbetween about 110° C. and about 150° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The second drying step may comprise drying the sheet at a temperature ofbetween about 110° C. and about 140° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The second drying step may comprise drying the sheet at a temperature ofbetween about 110° C. and about 130° C. for at least about 5 seconds, atleast about 30 seconds, at least about 1 minute, at least about 2minutes, at least about 3 minutes, at least about 4 minutes or at leastabout 5 minutes.

The second drying step may comprise drying the sheet using suitableknown machinery and processes.

The second drying step may comprise drying the sheet using one or bothof steam and heated air.

The sheet may have a width of at least about 20 mm.

Advantageously, the sheet may have a width of at least about 40 mm, atleast about 60 mm or at least about 80 mm.

The sheet may have a width of between about 20 mm and about 300 mm,between about 40 mm and about 300 mm, between about 60 mm and about 300mm or between about 80 mm and about 300 mm.

The sheet may have a thickness of at least about 50 microns.

Advantageously, the sheet may have a thickness of at least about 75microns, at least about 100 microns or at least about 125 microns.

The sheet may have a thickness of between about 50 microns and about 300microns, between about 75 microns and about 300 microns, between about100 microns and about 300 microns or between about 125 microns and about300 microns.

Advantageously, the method may further comprise the steps of: gatheringthe sheet transversely relative to a longitudinal axis thereof; andcircumscribing the gathered sheet with a wrapper to form a rod.

Advantageously, the method may further comprise the step of: severingthe rod into a plurality of discrete aerosol-generating rods.

The method may comprise gathering the sheet transversely relative to alongitudinal axis thereof and circumscribing the gathered sheet with awrapper to form a rod using conventional cigarette filter makingmachinery.

For example, the method may comprise gathering the sheet transverselyrelative to a longitudinal axis thereof and circumscribing the gatheredsheet with a wrapper using machinery for forming filter rods comprisinga gathered crimped sheet of paper of the type described in CH-A-691156.

The gathered sheet advantageously extends along substantially the entirelength of the aerosol-generating rod and across substantially the entiretransverse cross-sectional area of the aerosol-generating rod.

Advantageously, the aerosol-generating rod may be of substantiallyuniform cross-section.

The aerosol-generating rod may advantageously have a rod length ofbetween about 5 mm and about 25 mm, between about 5 mm and about 20 mmor between about 5 mm and about 15 mm.

As used herein with reference to the invention, the term “rod length” isused to describe the maximum dimension in the direction of thecylindrical axis of the aerosol-generating rod.

The aerosol-generating rod may advantageously have a rod diameter ofbetween about 6 mm and about 10 mm, between about 6 mm and about 9 mm orbetween about 6 mm and about 8 mm.

As used herein with reference to the invention, the term “rod diameter”is used to describe the maximum dimension in a direction substantiallyperpendicular to the cylindrical axis of the aerosol-generating rod.

The method may comprise circumscribing the gathered sheet with a porouswrapper.

The method may comprise circumscribing the gathered sheet with anon-porous wrapper.

The aerosol-generating rod may be used as a component of anaerosol-generating article.

The aerosol-generating rod may advantageously be used as anaerosol-generating substrate in an aerosol-generating article.

The aerosol-generating rod may particularly advantageously be used as anaerosol-generating substrate in a heated aerosol-generating article.

As used herein, the term “aerosol-generating substrate” is used todescribe a substrate capable of releasing volatile compounds uponheating to generate an aerosol.

An inhalable nicotine-containing aerosol is generated upon heating of anaerosol-generating substrate comprising the aerosol-generating rod.

A number of aerosol-generating articles in which an aerosol-formingsubstrate is heated rather than combusted have been proposed in the art.Typically in heated aerosol-generating articles, an aerosol is generatedby the transfer of heat from a heat source, for example a chemical,electrical or combustible heat source, to a physically separateaerosol-generating substrate, which may be located within, around ordownstream of the heat source.

The aerosol-generating rod may be used as an aerosol-generatingsubstrate in a heated aerosol-generating article comprising acombustible heat source and an aerosol-generating substrate downstreamof the combustible heat source.

For example, the aerosol-generating rod may be used as anaerosol-generating substrate in an aerosol-generating article of thetype disclosed in WO 2009/022232 A2 which comprises a combustiblecarbonaceous heat source, an aerosol-generating substrate downstream ofthe combustible heat source and a heat-conducting element around and incontact with a rear portion of the combustible carbonaceous heat sourceand an adjacent front portion of the aerosol-generating substrate. Itwill be appreciated that the aerosol-generating rod may also be used asan aerosol-generating substrate in heated aerosol-generating articlescomprising combustible heat sources having other constructions.

The aerosol-generating rod may be used as an aerosol-generatingsubstrate in a heated aerosol-generating article for use in anelectrically-operated aerosol-generating system in which theaerosol-generating substrate of the heated aerosol-generating article isheated by an electrical heat source.

For example, the aerosol-generating rod may be used as anaerosol-generating substrate in an aerosol-generating article of thetype disclosed in EP 0 822 760 A2.

An aerosol-generating article may comprise an aerosol-forming substratecomprising the aerosol-generating rod and one or more other elements.

The one or more other elements may include one or more of a supportelement, a spacer element, an aerosol-cooling element and a mouthpiece.

Advantageously, the method may further comprise the step of: texturingthe sheet prior to the gathering step. This may facilitate gathering thesheet transversely relative to a longitudinal axis thereof.

As used herein with reference to the invention, the term “texturing” isused to describe crimping, embossing, debossing, perforating orotherwise deforming the sheet. Textured sheets may comprise a pluralityof spaced-apart indentations, protrusions, perforations or a combinationthereof.

More advantageously, the method may further comprise the step of:texturing the sheet prior to the gathering step.

As used herein with reference to the invention, the term “crimped sheet”is intended to be synonymous with the term “creped sheet” and is used todescribe a sheet having a plurality of substantially parallel ridges orcorrugations.

Advantageously, the crimped sheet may have a plurality of ridges orcorrugations substantially parallel to the cylindrical axis of theaerosol-generating rod. This may advantageously facilitate gathering thecrimped sheet transversely relative to a longitudinal axis thereof.

The method may comprise texturing the sheet using suitable knownmachinery for texturing filter tow, paper and other materials.

The method may comprise crimping the sheet using a crimping unit of thetype described in CH-A-691156, which comprises a pair of rotatablecrimping rollers. However, it will be appreciated that the method maycomprise texturing the sheet using other suitable machinery andprocesses that deform or perforate the sheet.

Inclusion of sugar in the mixture may advantageously facilitatetexturing of the sheet.

Example

A sheet having the composition shown in Table 1 is prepared by a methodaccording to the invention:

TABLE 1 Percentage by weight Component on a dry weight basis (%)Cellulose powder 43.1 (average particle size 20 microns) Cellulosefibres 2 Nicotine lactate 3.2 Sorbitol 28.7 Guar gum 3 Glycerine 20

To prepare the sheet the cellulose fibres, glycerine, nicotine lactate(in solution) and water are placed in a tank and stirred for 1 minute ata speed of 1000 rpm. In a separate vessel the cellulose powder, sorbitoland guar gum are manually pre-mixed. The pre-mixed cellulose powder,sorbitol and guar gum is added to the tank comprising the cellulosefibres, glycerine, nicotine lactate (in solution) and water. Theresulting mixture is stirred under vacuum (0.8 mbar) for 4 minutes at aspeed of 5000 rpm.

The resulting slurry is cast onto a support surface and then dried toform a sheet.

The thickness of the sheet is about 175 microns.

The invention will be further described, by way of example only, withreference to the accompanying drawings in which:

FIG. 1 shows a schematic cross-section of apparatus for forming anaerosol-generating rod from a continuous sheet made by the method ofExample 1;

The apparatus shown in FIG. 1 generally comprises: supply means forproviding a continuous sheet; crimping means for crimping the continuoussheet; rod forming means for gathering the continuous crimped sheet andcircumscribing the gathered material with a wrapper to form a continuousrod; and cutting means for severing the continuous rod into a pluralityof discrete aerosol-generating rods. The apparatus also comprisestransport means for transporting the continuous sheet downstream throughthe apparatus from the supply means to the rod forming means via thecrimping means.

As shown in FIG. 1, the supply means for providing a continuous sheetcomprises a continuous sheet 2 made by the method of Example 1 mountedon a bobbin 4.

The crimping means comprises a pair of rotatable crimping rollers 6. Inuse, the continuous sheet 2 is drawn from the first bobbin 4 andtransported downstream to the pair of crimping rollers 6 by thetransport mechanism via a series of guide and tensioning rollers. As thecontinuous sheet 2 is fed between the pair of crimping rollers 6, thecrimping rollers engage and crimp the sheet 2 to form a continuouscrimped sheet 8 having a plurality of spaced-apart ridges orcorrugations substantially parallel to the longitudinal axis of thesheet through the apparatus.

The continuous crimped sheet 8 is transported downstream from the pairof crimping rollers 6 towards the rod forming means and fed through aconverging funnel or horn 10. The converging funnel 10 gathers thecontinuous sheet 8 transversely relative to its longitudinal axes. Thesheet of material 8 assumes a substantially cylindrical configuration asit passes through the converging funnel 10.

Upon exiting the converging funnel 10, the gathered sheet is wrapped ina continuous sheet of wrapper material 12. The wrapper is a paperwrapper and is fed from a bobbin 14 and enveloped around the gatheredcontinuous crimped sheet by an endless belt conveyor or garniture. Asshown in FIG. 1, the rod forming means comprises an adhesive applicationmeans 16 that applies adhesive to one of the longitudinal edges of thewrapper, so that when the opposed longitudinal edges of the wrapper arebrought into contact they adhere to one other to form a continuous rod.

The rod forming means further comprises a drying means 18 downstream ofthe adhesive application means 16, which in use dries the adhesiveapplied to the seam of the continuous rod as the continuous rod istransported downstream from the rod forming means to the cutting means.

The cutting means comprises a rotary cutter 20 that severs thecontinuous rod into a plurality of discrete aerosol-generating rods 22of unit rod length or multiple unit rod length.

1.-15. (canceled)
 16. A method of making a nicotine containing sheet,comprising: combining a source of nicotine salt having a cellulosecontent of less than about 5% by weight on a dry weight basis with aseparate source of fibrous material having a nicotine salt content ofless than about 5% by weight on a dry weight basis to form a mixture;and drying the mixture to form a sheet.
 17. The method according toclaim 16, wherein the source of nicotine salt comprises one or morenicotine salts of monoprotic carboxylic acids selected from the groupconsisting of acetic acid, benzoic acid, gallic acid, lactic acid,lauric acid, levulinic acid, palmitic acid, pyruvic acid, sorbic acid,and stearic acid.
 18. The method according to claim 16, wherein a weightratio of fibrous material to nicotine salt in the mixture on a dryweight basis is between about 15:1 and about 1:3.
 19. The methodaccording to claim 16, wherein the source of nicotine salt comprises oneor more monoprotic nicotine salts.
 20. The method according to claim 16,wherein the combining comprises combining cellulose powder with thesource of nicotine salt and the separate source of fibrous material toform the mixture.
 21. A sheet formed according to claim 20, wherein thecellulose powder has an average particle size of less than about 60microns.
 22. The method according to claim 16, wherein the combiningcomprises combining sugar with the source of nicotine salt and theseparate source of fibrous material to form the mixture.
 23. The methodaccording to claim 22, wherein the sugar comprises mannitol, sorbitol,or a combination thereof.
 24. The method according to claim 16, whereinthe combining comprises combining a binder with the source of nicotinesalt and the separate source of fibrous material to form the mixture.25. The method according to claim 24, wherein the binder comprises oneor more natural gum binders selected from the group consisting of guargum, xanthan gum, and gum arabic.
 26. The method according to claim 16,wherein the combining comprises combining an aerosol former with thesource of nicotine salt and the separate source of fibrous material toform the mixture.
 27. The method according to claim 16, wherein thedrying comprises drying the mixture at a temperature of between about100° C. and about 170° C. for at least about 2 minutes.
 28. The methodaccording to claim 16, further comprising: casting the mixture onto asupport surface prior to the drying.
 29. The method according to claim16, further comprising: gathering the sheet transversely relative to alongitudinal axis thereof; circumscribing the gathered sheet with awrapper to form a rod; and severing the rod into a plurality of discreteaerosol-generating rods.
 30. The method according to claim 29, furthercomprising: crimping the sheet prior to the gathering.